Technology Solutions TEK-DP...Tek-Trol’s orifice plates comply with Latest AGA 3/API 14.3 or ISO...

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IntroductionTek-Trol’s Tek-DP 1610A Smart Orifice Meters offer superior flow measurement in a range of gas and liquid applications. Built on the oldest and proven differential pressure measurement technique, the Tek-DP 1610 series is constructed to allow ease of orifice plate replacement, reliable measurement, and exceptional performance.

Tek-Trol provides a comprehensive orifice metering solution by assembling orifice fittings with upstream/downstream meter runs, an orifice plate and a flow conditioner (or a straightening vane) in accordance with the latest AGA 3 and ISO 5167 standards. All components of orifice meters are available in a com-plete range of materials, sizes and pressure ratings to meet the application needs.

Measuring PrincipleThe Tek-DP 1610A Smart Orifice Meters work on the principle of differential pressure measurement. Based on Bernoulli’s theory of conservation of mass and energy in a closed pipe, the obstruction to the flow of fluid leads to an increase in the flow velocity (i.e. V2 > V1 ), thereby creating a pressure drop. The fluid flow rate depends on the static pressures at upstream and downstream, minimum cross sectional area and temperature. It is calculated by applying the law of conservation of mass and energy.

The relation between the differential pressure and flow rate is represented as the below expression,

Δp α Q2

The differential pressure generated, ∆p, is proportional to the square of mass flow rate, Q. In simple terms, for a given size of restriction, higher the differential pressure, ∆p, higher is the flow rate, Q.

Fig.1. Differential Pressure Measurement

UpstreamDownstream

Pipe

Tap

Flow

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1610A Single Chamber Orifice Fitting

OperationThe complete orifice meter assembly is comprised of an orifice plate that is positioned between the two flanges with the help of an orifice plate carrier and other essential components such as the flow condi-tioner, pressure taps, and the transmitter. The orifice plate acts as a restriction to the flow of the fluid.

The fluid in motion passes through an abrupt obstruction created by the orifice plate. This results in a sudden pressure drop, which varies with the flow rate. As the fluid converges to pass through the bore, its velocity increases. The flow continues to converge at the downstream of the plate until it reaches the vena contracta point (the point of maximum convergence) and then expands to rejoin the pipe wall. The pressure taps measure static pressures of the upstream and downstream flow. The differential pressure is proportionate to the flow rate and can be determined by the equations defined in defined in AGA 3 and ISO 5167 standards.

Plate Thickness, EDownstream Face, B

Tap

Upstream Face, A

Bevel Angle, F

Orifice Thickness, e

Pipe

Dia

met

er, D

Bore

Dia

met

er, d

Pipe Axis

Direction of Flow

Orifice Plate PipePipe Internal Bore

The Tek-DP 1610A Single Chamber Orifice Fittings are the sin-gle chamber devices designed for precise flow measurement in oil and gas applications with a simple plate removal technique. These fittings are suitable in liquid flow measurement as well. Tek-Trol ensures that each single chamber fitting undergoes rig-orous testing under pressure conditions to provide maximum safety to the user and the system.

The single chamber fittings are manufactured in accordance with latest ANSI, AGA 3/API, and ASTM standards for pressure tap integrity, positive plate seal, seal protrusion, and eccen-tricity. These single chamber orifice fittings can be installed in vertical or horizontal lines and are available in a wide range of pipe sizes from 2" to 48". These fittings allow ease of orifice plate replacement or inspection in a depressurized flow line without physically removing the meter from the line. The Tek-DP 1610A Single Chamber Orifice Fittings are best used in the applications where replacing the orifice plate under pressure conditions is risky and a nominal shutdown time is acceptable. The plate re-moval procedure does not require removal of the flange bolts or spreading of flanges. This prevents potential leakage of process fluid and safeguards the operators.

Fig.3. Single Chamber Orifice

Fig.2. Operation of an Orifice Flow Meter


The location, size and construction of the orifice meter pipe taps can affect the meter’s accuracy. Tek-Trol Orifice Fittings are supplied are offered with two ½" NPT flanged taps per side are standard, two additional ½" NPT taps can be provided as optional to connect additional field devic-es. Taps sizes for 2" and 3" fitting are 0.375" inside diame-ter and for 4" and larger sizes these taps are center bored to. 500" inside diameter. Fittings are manufactured with Tap located 1" from the face of the orifice plate with accu-racy/tolerance in line with AGA 3 requirements .

For the smaller models of size 2" to 6", by removing bolts and a camping bar, the operator can "manually extract" the orifice plate from the fitting, inspect and replace in a short time. However, 8" and larger models incorporate a rack and pinion gear system to handle the sizable weight of large orifice plates and carriers.

The "unique design" of the Tek-DP 1610A Sin-gle Chamber Orifice Fittings allow an accurate and secured positioning of the plate every time it is re-placed after inspection ensuring unchanged meter performance.

The standard O-ring seals used in these fittings pro-vide superior sealing capability by eliminating the requirement of gasket maintenance and possibility of screw breakage. However, gaskets are available to use when required.

Features

Applications

• Highly reliable and field-repairable

• Rack and pinion configuration for easy plate replacement

• Ensures plate remove without spreading the flanges

• Short operational downtime

• Eliminates liquid or gas leakage possibility

• Offers versatility of line sizes

• Oil and gas custody transfers

• Water, wastewater treatment plants

• Shale liquid production

• Chemically active and corrosive liquid transfers

Fig.4. Rack and Pinion Gear System

Fig.5. Carrier Plate

½" NPT1"

Carrier Plate

Orifice Plate


Dimesional Drawing

• Single Chamber Fitting

Technical Specifications

Body Materials A216 WCB, A216 WCC, A352 LCC, A358 CF8M, A995 Gr4A, A995 Gr6A, Custom materials available

Internal Parts AISI 4130 Carbon Steel, 316 or A351 Stainless Steel

Tap Connections Two ½" NPT per side standard, 4 pairs available as options

Fitting Sizes and ANSI Class 2" to 48", 150 to 2500 ANSI, Larger sizes available on request

Operating Temperature Standard -20 °F to 100 °F (-28 °C to 37 °C), optional -40 °F to 1200 °F (-40 °C to 648 °C)

Orientation Vertical or horizontal

Process Media Liquids and Gases

Line Bore I.D. Tolerance In conformance with AGA 3 and ISO-5167 Latest Edition

Eccentricity Repeatability In conformance with AGA 3 and ISO-5167 Latest Edition

CH

B FlangeRF/RTJ

Flange x WN WN


Features• Robust design

• Easy to install

• Cost effective

• Proven leak-proof connection when used with seals

• Available in all sizes and materials

• Suitable for viscous, corrosive fluids, and gases


Size 1" to 48", Larger line size available on customer request

Material SS304L, SS316L, Duplex, Super Duplex, Monel, Inconel, and Hastelloy (Other material available on application)

Bore Concentric, Eccentric, Quadrant

The Universal Type Series Orifice Plates are manufactured for use in Single Chamber and Dual Chamber Or-ifice Fittings. Tek-Trol’s fail-safe concentric design of universal type orifice plates eliminates the possibility of improper plate orientation and positioning. Tek-Trol supplies orifice plates in standard 304SS and 316SS cor-rosion-resistant material in a range of plate sizes from 1" to 48" to fulfill application needs. The orifice plates are also available in custom materials such as Duplex, Super Duplex, Monel, Inconel, and Hastelloy. The seals, crucial to maintain the leak-proof connections, are available in all plate sizes and types (soft seat valve seals, O-ring seals).

Although there does not appear to be any experimental evidence to define the smoothness necessary for upstream face of an orifice plate, it is recognized that a smooth, non-striated finish is desirable. According to latest AGA 3, the Surface finish of orifice plate should be preferably less than 25 micro inches.

Fig.6. Universal Type Orifice Plate

Tek-Trol’s Orifice Plates and Seals are play a key role in maintaining the performance and durability of orifice flow meters. Tek-Trol’s orifice plates comply with Latest AGA 3/API 14.3 or ISO 5167-1 Edition to ensure max-imum accuracy. The orifice plates are responsible to create a restriction in the fluid flow path for generating a differential pressure, which is measured across the plate through two taps located on the Single Chamber Orifice Fitting near the constriction.

Types of orifice plates include conical, quadrant-edge, and square-edged entrant concentric, eccentric, and segmental orifice plates. Tek-Trol’s orifice plates and seals are compatible with all orifice-fitting variants- Single Chamber, Dual Chamber and Orifice Flange Unions.

Orifice Plates and Seals


Meter RunsTek-Trol’s standard and custom fabricated meter runs are compatible with all orifice-fitting models to meet specific performance needs of challenging metering applications. These meter runs adhere to the highest quality specifications set by AGA 3/API 14.3 and ISO 5167-1 to ensure adequate length, precise alignment, and smooth finish for enhanced measurement reliabil-ity.

Tek-Trol’s meter-runs are manufactured to meet the appropriate upstream/downstream straight pipe length, surface requirements, roundness, and flow tolerance. As manufactured in a single unit, these pre-assembled meter runs allow rapid installation and reduce startup costs. These rigorously tested and inspected meter-runs are exceptionally accurate, extremely reliable, and ready for service.

Meter Tubes are built out of meter tubes out of carefully selected pipe and available in Hot Finish, Cold Finish and Honed Options as per the application requirements. All Tek-Trol Meter Tubes are are built with roundness (ID) tolerance and eccentricity repeatability In conformance with AGA 3 and ISO-5167 Latest Editions. The meter run surface finish with nominal diameters of 12" or smaller are offered in 250 micro inches or better with a minimum roughness of not be less than 34 micro inches and for meter runs with nominal diameters larger than 12" these are offered with 500 micro inches or better with minimum roughness not less than 34 micro inches for all Beta ratio.

Tek-Trol’s two section meter runs are compatible with all styles of orifice fittings and plate holders. These accurate, dependable instruments have a section of meter tube on either sides of the orifice fitting. Each tube adheres to an upstream and downstream of the minimum length prescribed by API 14.3. Longer upstream meter tube provides adequate length for stabilizing the flow before it passes through the orifice plate.

Fig.7. Two Section Meter Run

Tek-Trol’s three section meter runs incorporate an additional component, a flow conditioner, which helps reducing the overall upstream meter tube length. The flow conditioner plate inserted on the upstream effec-tively minimizes swirls and turbulence to ensure steady flow profile. These meter runs are utilized in highly tur-bulent flow and congested places where maintaining the standard upstream length is impossible.

Fig.8.Three Section Meter Run

The meter runs can be offered with with single or multiple downstream outlets in ½", 1" and one ¾" branch connection on the downstream spool for pressure, temperature, diagnostic taps. Our custom meter tube de-sign capability allows us to fabricate these outlets with weldolets, sockolets, RF/RTJ flanged outlets, threado-lets with break flange options in any size and orientation. Meter Tubes are supplied standard with specification plate fixed on the upstream of the orifice fitting. These spec plates provide information on the pipe schedule, pressure rating, maximum beta, maximum orifice and other information essential to proper operation once installed at site



Design Code ISO-5167, API 14.3 (AGA-3)Configuration 2 Pc or 3 Pc design

Surface Finish

For meter runs with nominal diameters of 12" or smaller: 250 micro inches with a minimum roughness of not be less than 34 micro inchesFor meter runs with nominal diameters larger than 12" 500 micro inches or better with minimum roughness not less than 34 micro inches for all Beta ratio.

Line Size 2" to 48" (Larger Line Size Available On Application)Pressure 150# to 2500# (Higher Pressure Available On Application)

Pipe Material Carbon Steel, Stainless Steel, Duplex, Low Temp Steel and Other Material Available

Studs, Nuts Carbon steel, Stainless with/without Teflon/ Hot Dip Galvanized options.

Features• Ensure optimum compatibility with all products

• Eliminates the measurement inaccuracies recorded in small orifice line installations

• Inserts sufficient pipe length to reduce distortions due to pipe roughness

• Eliminates the possibility of plate misalignment

• Avoids possible leak points


Fig.9. Straightening Vanes

Features• Reduce swirls and turbulence

• Condition upstream flow profile

• Reduce upstream meter run length

• Enhance measurement accuracy


Line Size 2" to 48", Larger size available on request

Process Media Natural gas, air, crude oil, water, light hydrocarbons

Performance In accordance with AGA 3/API 14.3, ISO 5167

Maximum Pressure ANSI 1500

Maximum Pressure Stainless Steel (304, 316 and duplex), Optional materials available

Tek-Trol’s straightening vanes are designed to be in-stalled in the upstream orifice meter runs to serve dual purpose: (1) They convert complex, turbulent flow into a smoothened, reliable flow pattern and (2) They re-duce upstream pipe length requirements.

Tek-Trol’s straightening vanes are available in standard corrosion resistant materials including 304, 316 stain-less steel and carbon steel making them suitable for wide types of gas and fluid applications. These straight-ening vanes are manufactured in both line-mounted and flanged models, in strict compliance with API 14.3 and ISO 5167 standards. The line-mounted model is inserted in upstream pipe and secured with the help of screws. The flanged type model is flanged between upstream line flanges.

Straightening Vanes


Fig.10. Types of flow conditioning plates

Flange TypeInserting Type Ring Type

Features• Easy to install, field repairable

• Cost effective

• Minimize swirls and turbulence

• Eliminate effects of flow disturbance

• Suitable in all liquid and gas applications with no upper limit on Reynolds number

• Reduces upstream meter run length


Flow ConditionersFlow Conditioners

Line Size 2" to 48", Larger size available on request

Process Media Natural gas, air, crude oil, water, light hydrocarbons

Performance In accordance with AGA3/API 14.3

Maximum Pressure ANSI 1500

Maximum Pressure Stainless Steel (304, 316 and duplex), Optional materials available

Tek-Trol’s Flow Conditioner Range is meticulously manufactured for converting an irregular upstream flow to a predictable downstream flow. These flow conditioners are available from 2" to 48" pipe sizes and in a variety of materials such as duplex, 304SS and 316SS, making these suitable for all applications including extremely corrosive environments. Properly selected and installed flow conditioners eliminate swirls and turbulence; making the flow profile much more reliable. The complete flow conditioner range is suitable and essential for any fluid measurement scenario including water, crude oil, petroleum, air, light hydrocarbons and natural gas for providing stable downstream flow. This design fully develops the flow profile and significantly reduces upstream pipe length requirements.

Tek-Trol offers flange type, inserting type and ring type of flow conditioners in compliance with AGA3/API 14.3 standards to adapt with various configurations.


• Install the orifice meter between the upstream and downstream meter run sections. Place the fitting in line with the two flange taps, positioning the instruction plate facing upward.

• It is possible to install the fitting in either horizontal or vertical position. Ensure that the flow arrow on the outer surface of the fitting corresponds to the direction of flow in the pipeline.

• Use of vertical mount is recommended for wet gas measurement to prevent moisture formation against the orifice plate.

• Ensure that the lower cavity of the fitting is free of dust and debris, before inserting the orifice plate into the fitting.

Installation Guidelines

TekvalSys-DPTek-Trol’s extremely powerful flow validation tool, TekValSys-DP, based on Prognosis, converts a mechanical DP flow measurement device into a smart, comprehensive flow measurement solution. The TekValSys-DP can be utilized in many DP Metering applications including single-phase gases, liquids, steams, heavy oils, and water-in-oil mixtures. The TekValSys-DP can be used with any device creating differential pressure such as orifice, cone, pitot tube, venturi or flow nozzles. The system requires two additional differential pressure mea-surements in addition to the traditional DP transmitter.

The TekValSys-DP software available in three versions, namely, micro, light and pro, can be easily integrated into an existing DP control system. Once installed, the TekValSys-DP system provides real-time alerts of meter measurement and performance shifts, making easy monitoring and reducing maintenance overhead.


Customer Service and Support

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Technology Solutions TEK-DP...Tek-Trol’s orifice plates comply with Latest AGA 3/API 14.3 or ISO...

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Transcript of Technology Solutions TEK-DP...Tek-Trol’s orifice plates comply with Latest AGA 3/API 14.3 or ISO...